sterlite technologies limited - national power training … co-efficient of expansion 11.5 x 10-6...
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www.sterlitetechnologies.com April 2012 1
Sterlite Technologies Limited
www.sterlitetechnologies.com April 2012 2
Very high cost to install new Power Lines
Difficulty in acquiring Tower sites- Right of Way
Time involved in constructing new Power Lines
Provision for future contingencies
Usage of High
Temperature –
Low Sag(HTLS)
Conductors
Increasing demand for Electrical power generation and transmission, but......
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High tensioning on
conductors
INSUFFIFICENT CAPACITY
TOWER TENSION
T&D LOSSES
AND CDM
REQUIREMENT OF NEW LINES
Existing lines required to carry
more current
Green energyFuture proofing
Need to develop & use specialty materials in power transmission lines
Addressing Key industry challenges
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Shift from ACSR to HTLS
HTLS Conductors
Ampacity
Sag tension
InstallationReliability
Economics
Easy and Rapid Installation
Low Sag-Tension Property
Equally Reliable
Low Line loss
High Current Carrying Capacity
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HTLS Conductors – New Generation Conductors
RECONDUCTORING
• Enhanced Current Carrying Capacity for the samediameter/weight.
• No modification/reinforcement to the existing towers.
NEW LINES
• Enhanced Current Carrying Capacity.
• Reduction in per unit transmission cost.
• Higher Corrosion Resistance.
• Shorter Project Duration.
• Additional capacity of ~ 100% is reserved
for future demand
GREEN SOLUTIONS
• Low loss leading to lower carbon emissions.
• Run at lower temperature for the same current.
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STERLITE’S PORTFOLIO
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NEW LINES RECONDUCTORING GREEN SOLUTIONS
STACIR STERLITE ECOTMTACSR
GAP ACCC®ACSS
ACCC®STERLITE ECOTM
ACCC®
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SUPER THEMAL ALUMINIUM CONDUCTOR INVAR REINFORCED
This low sag conductor is manufactured from Al-Zr(Aluminium Zirconium) alloy rods. The
conductor comprises of an strong inner Invar steel core and concentrically arranged STAL
strands forming the outer layer of conductors.
BENEFITS:
• Preffered for reconductoring applications.
• No modification/reinforcement is required
to the existing towers.
• Can carry 100% more current as that of
ACSR of the same size,while maximum sag
and maximum working tension remains the
same as that of ACSR.
Super-thermal
resistant Al alloy
wire(STAL)
STACIR
Aluminium Clad
INVAR Core
STACIR
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Application: Replacing the installed ACSR/AAAC conductor by STACIR equivalent
conductor. STACIR is a solution to up rate existing transmission lines in a short time
frame. Modification or reinforcement of the towers is not required.
Performance: With the same tower loadings a STACIR conductor can carry up to two
times the rating of a conductor with the same diameter it would replace.
Sterlite’s experience: In India Sterlite has supplied approximately 200 Km of STACIR
conductor equivalent of ACSR Panther for the increase of the transmission capacity of
the 132kV Shapurnagar – Chinthal, 132kV Ghanapur – Bandhlaguda & 132kV Bootpur
to Balanagar lines of Andhra Pradesh Transmission Corporation, India.
Application case : Sterlite STACIR
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Re-conductoring solution: STACIR
Possibility to increase the
capacity of existing lines by 100%
Excellent Sag properties due to
INVAR core
Modification or reinforcement of
the towers is very limited or not
required.
Benefits
Re-conductoring solution for 132kV lines of APTRANSCO
STACIR
Wolf
30/7/2.59
mm
ACSR Wolf
30/7/2.59
mm
Ampacity
(amperes)843 362
Sag (m) 4.83 5.42
Tension
(Kg)3723 3723
Condition: Span 275m, Tension 36°C 100% wind, Ambient
55°C, Operating Temp: ACSR Panther – 75°C & STACIR -
210°C
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THERMAL ALLOY CONDUCTOR STEEL REINFORCED
TACSR conductors are the conductors wherein the inner core is composed of galvanised
steel and outer layers are composed of thermal-resistant aluminium alloy.
Thermal Aluminium Alloy Wire
Wire-Galvanised Steel
TACSR
BENEFITS:
• Ampacity is almost 50% more – Higher
Power Transfer Capacity.
• Higher capacities line built can cater to
future increased demand of power.
• Can be used with existing tower designs.
TACSR
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New lines solution: TACSR
Ampacity is almost 50% more –
Higher Power Transfer Capacity.
Higher capacities line built can
cater to future increased demand
of power.
Can be used with existing tower
designs.
Benefits
New line solution for different voltage levels
TACSRACSR
Moose
Ampacity
(amperes)1509 764
Sag (m) 13.91 12.86
Tension
(Kg)7392 7392
Condition: Span 400m, Tension 32°C 100% wind, Ambient
45°C, Operating Temp: ACSR Moose – 75°C & ACSS -
210°C. Quad configuration
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Inner core – TACSR & STACIR
Properties Galvanised Steel Galvanised Steel (ST6 C)
Aluminium Clad Invar
Tensile Strength (MPa) 1226 1700 1184
Conductivity(% IACS) 8 8 14
Linear Co-efficient of Expansion
11.5 x 10-6 11.5 x 10-6 3.7 x 10-6
Young’s Modulus(Kg/mm2)
21000 21000 15500
STACIR is designed with Al clad INVAR having low thermal co-efficient expansion at 2100
C which enables it to maintain the SAG equal to equivalent ACSR.
TACSR can be designed with STC 6 core to maintain the sag equal to ACSR, even when
while it operate at 1500 C.
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ALUMINIUM CONDUCTOR STEEL SUPPORTED
ACSS conductors are manufactured from Annealed Aluminium 1350 wires and an inner
high tensile strength core of Galfan(Zn 5% Al Mischmetal) coated steel wires.
BENEFITS:
• Preffered for reconductoring as well as new
line applications.
• Offers low sag, even when operating at upto
2500 C.
• Alumnium wires of ACSS have an increased
conductivity of 63% IACS.
ACSS
ACSS/TW and ACSS
1350 Annealed Al Wire
Mischmetal Steel Wire
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Application case : Sterlite ACSS
Application: ACSS for new lines in order to reduce losses/transfer more than double
power, replacing conventional conductors like ACSR/AAAC.
Performance: With the same tower loadings an ACSS conductor can carry up to two
times the rating of a conductor with the same diameter it would replace.
Sterlite’s experience: In India, Sterlite has supplied 235 Km of ACSS conductor
equivalent of ACSR Moose for the increase of the transmission capacity of the 400kV
LILO of D/C Korba – Birsingpur line of Bharat Aluminium Company Limited. Sterlite ACSS
will be the first HTLS to be deployed in upgradation of bus bar of 220kV S/S of
Maharashtra State Electricity Transmission Co. Ltd.
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STER ECOTM
Trapezoidal shaped special aluminium alloy containing magnesium, silicon and copper stranded with round core which provides compactness to the extent of 96%.
Innovative, efficient, low loss and an economical solution for re-conductoring power lines and constructing new lines.
Higher efficiency enables significant savings when substituted in grid systems for normal ACSR or AAAC conductors.
BENEFITS:
• Up to 30% less I2R losses for same sized
conductor
• For same output runs cooler by 5-10OC, hence
lower carbon emissions
• Contributing to greenhouse gases
• Can be deployed with existing structural designs
STER – ECOTM
ACSR DogSterlite Eco
Cond.
Ampacity
(amperes)284 284
Temp 0C 75 68.5
I2R Losses
(kw/km)80.74 57.89
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SUPER THEMAL ALUMINIUM CONDUCTOR INVAR REINFORCED
GAP conductors are manufactured from (super) thermal-resistant aluminium alloy wire
and the high strength steel core. There is a small annular gap filled with grease between
the high-strength steel core and the first layer of trapezoidal-shaped aluminum strands.
The principle of the Gap-type conductor is that it can be tensioned on the steel core alone
during erection.
High Strength Steel Wire
GAP TYPE CONDUCTOR
(Super) Thermal resistant aluminium alloy wire
GAP
Gap filled with grease
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Re-conductoring solution: GAP
Possibility to increase the
capacity of existing lines by 50 to
100%
Excellent Sag properties
Modification or reinforcement of
the towers is very limited or not
required.
Benefits
Excellent option for re-conductoring of old lines
GAPACSR
Moose
Ampacity
(amperes)1574 797
Sag (m) 13.06 13.25
Tension
(Kg)9421 9421
Condition: Span 400m, Tension 9421 kg, 32°C no wind,
Ambient 45°C, Operating Temp: ACSR Moose – 75°C &
GAP - 210°C ;
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DULL CONDUCTORS
Dull conductors are either mechanically or chemically treated to produce reduced
reflectivity. The finished conductor surface is blasted with a very fine mild abrasive grit
producing a dull matte gray finish.
BENEFITS:
• Increase in current carrying capacity
in the range of 5% due to increase in
emissivity of the conductor.
• Aesthetic Appeal
DULL CONDUCTOR
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• These are high ampacity, low loss
hybrid conductors
• Composition: Carbon, glass fiber and
trapezoidal shaped aluminum, that
are resistant to environmental
degradation.
• These conductors can reduce line
losses up to 40% compared with
conventional conductors of the same
diameter and weight.
Technology patented by CTC Cable Corporation, USA and under license to
Sterlite Technologies.
ACCC® conductors
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• 28% More Aluminum = Greater
Capacity, Reduced Losses, & Cooler
Temperatures
• 25% stronger & 60% lighter vs.
traditional steel core = fewer or lower
structures
• Lower Coefficient of Thermal
Expansion = Less Sag at Higher
Temperatures
These conductors find use in new line installations and re-conductoring
applications.
ACCC® conductors
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+35% +80% +100%
Conductor Performance(Power Transfer)
ACSR
TACSR
ACCR
ACCC
STACIR
CONDUCTOR
POWER TRANSFER at max. operaing temp.(KW/ckt)
ACSS
+90%
GAP
+70% +90% +100%
Conductor Performance(Line Loss)
ACCC
ACCR
STACIR
ACSR
ACSS
TACSRCONDUCTOR
Line Losses at same ampacity (KW/ckt)
GAP
X 4.25 X
Conductor Price
ACSR
TACSR
ACCC
ACCR
STACIR
CONDUCTOR
PRICE
3.75 X2.5 X2 X
GAP
ACSS
COMPARISION OF DIFFERENT HTLS CONDUCTORS
INFERENCE:• ACCC will give us lowest line losses at the same amperage but considering the price also, GAP serves as the most economical & efficient conductor.
•To draw maximum power STACIR is the best option but again its price limits economic feasilibility. ACSS can be a economical option. Only problem is its sag which is more than eq. ACSR.
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Summary: Comparison of Conductors
Properties ACSR Moose TACSR Al59ACCC
DelhiACSS/TW STACIR GTACSR
Cross Sectional Area
(Sqmm)597.0 597.0 594.0 738.4 614.6 597.0 672.0
Conductor Dia (mm) 31.77 31.77 31.70 31.4 28.62 31.77 31.50
Weight (kg/km) 2004.0 2004.0 1640.0 1996.0 1985.3 1956.0 2179.0
UTS (kgf) 16432 16557.6 14545 17166.6 11462.8 15549 18175.3
DC Resistance @ 20° C
Temp (ohms/km)0.05595 0.05564 0.05026 0.04260 0.05140 0.05409 0.04780
Maxiumum Operating
Temperature (˚C)75 150 95 175 210 210 210
Current Carrying
Capacity (Amps) at 75 °C764 766 806 896 775 777 822
Current Carrying
Capacity (Amps) at
Maximum operating
Temperature
764 1511 1103 1950 1846 1869 1979
Sag (Span = 400m) at
Maximum operating
Temperature
13.25 14.00 13.55 13.04 13.95 12.30 13.06
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• Current requirement is known = optimal resistance
• Focus on tower loading: height & length of span
• HTLS's lower sags = lower towers or longer spans
• This translates into capital expense savings
Optimisation-New line with HTLS Conductors
ACSR Conductor plan
HTLS lower tension = same spans but lower towers
HTLS lower tension = longer spans with same towers
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THANK YOU